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EV Battery Cooling Solutions

Electric vehicle battery packs require thermal management to regulate temperature for optimal performance and safety. There are three common battery cooling methods: convection, oil flooding, and water-based coolant circulation. Tab cooling with a water-based coolant or refrigerant circulated through a cold plate offers benefits over surface cooling. The cooling system uses an electric pump to circulate coolant through the battery and components, a radiator and fan to cool the coolant, and controls temperature with a thermostat. Maintaining an optimum sub-ambient temperature is important for battery performance and longevity.

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Rahul Pawar
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251 views14 pages

EV Battery Cooling Solutions

Electric vehicle battery packs require thermal management to regulate temperature for optimal performance and safety. There are three common battery cooling methods: convection, oil flooding, and water-based coolant circulation. Tab cooling with a water-based coolant or refrigerant circulated through a cold plate offers benefits over surface cooling. The cooling system uses an electric pump to circulate coolant through the battery and components, a radiator and fan to cool the coolant, and controls temperature with a thermostat. Maintaining an optimum sub-ambient temperature is important for battery performance and longevity.

Uploaded by

Rahul Pawar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Cooling System

• Electric vehicles use large batteries to store energy. The energy flowing
into the battery pack as it is charged either from regenerative braking or
from the grid and discharged from the pack to power the vehicle and its
accessories is measured by electrical current and voltage.
• Most lithium battery cells cannot be fast-charged when they are less than
5oC and cannot be charged at all when they are below 0oC. Lithium cells
also begin to degrade quickly when their temperature is above 45oC.
• There are 3 common battery thermal management methods used today:
1. Convection to air either passively or forced.
2. Cooling by flooding the battery with a dielectric oil which is then pumped out to a heat
exchanger system.
3. Cooling by the circulation of water-based coolant through cooling passages within the
battery structure
• Air cooling is not suitable for most new high-performance applications due
to the power density required and the inability to cope with a wide range
of ambient temperatures.
• The coolant can be used to remove heat from the pack and to also provide
heating of the pack for fast charging at low temperatures.
• Tab cooling of the cells offers significant benefits over surface cooling as it
prevents a temperature gradient developing between the layers of the
cell.
• Tab cooling is best achieved by a water-based coolant or an organic
refrigerant circulated through a cold plate system built into the battery
pack by a pump.

Figure: High-Efficiency electric pumps


manufactured by AVID Technology
Figure: Sample of battery arrangement system
• Cooling Medium:
1. Water-glycol
2. Refrigerent
• An electric coolant pump that can generate both high flow rates and also
high static pressures is needed.
• Once the coolant has passed through the battery pack it is then circulated
through a heat exchanger where heat is transferred to ambient airflow
which is being blown by a fan, sometimes a refrigerant chiller system will
be used to achieve sub-cooling.
• 2 phase cooling is needed to allow the battery to be kept at an optimum
temperature that is below ambient.
Components in cooling system
• Fan
• Radiator (To cool the coolant)
• De-aeration tank
• Water Pump
• Liquid coolant
• Thermostat (to control the temperature of
coolant)
eCP80 – Sealless Electric Water Pump(AVID Technology)
Battery Thermal Management Systems (BTMS)
• Functions:
1. Cooling
2. Heating
3. Insulation
4. Ventilation

• Technologies of BTMS:
1. Air Cooling and Heating
2. Liquid Cooling and Heating

Figure: Passive and active liquid cooling system


3. Combined Liquid System (CLS)

Figure: The combined liquid cooling system


4. PCM Model (CLS+PCM)

Figure: The combined liquid cooling system


Cooling system

• Two pumps(One for Battery and electronic control unit other for PCS
power conversion system includes cooling of the lubrication oil and
electronic parts such as inverter module and charger module)
•A separate pump is used for lubrication of gearbox
•Control Valve(4-way)
•Two internal lines
•Two external lines
Flow chart for Cooling system
Surge
Tank

Electric Pump

Cooling Fan used


Radiator
to cool liquid

Single Power Inverter module Return to


surge tank

Power Module(DC Converter)

Onboard Charging Module

Drive Unit (Motor)

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